Packaging with its single use component, is one of the most significant contributors to the waste worldwide. Rising consumer awareness about the environmental impact of plastic packaging and strict government regulations has put packaging on the foremost agenda of the Fact Moving Consumer Good (FMCG) companies. Thus, companies are looking for sustainable packaging options to minimize the environmental impacts. Conventional flexible packaging structures are made up of different layers which are difficult to separate and in turn difficult to sort and recycle with current recycling infrastructure across nations. In the current research work, redesign or rethink concept is used for creating a sustainable packaging structure by replacing the present multi-material structure with a mono-material Poly Propylene (PP) based multi-layer packaging material. With mono-material based structure all of the above issues are resolved and this helps to create a closed loop economy which is ultimate objective of sustainable development.